Sofia Martinez
Plastic is everywhere, and it's a problem. Only 2 out of the 7 types of plastic can be recycled, and a mere 9% of the billions of tonnes of plastic produced in recent decades were recycled. The rest ends up in landfills, natural environments, or is incinerated, causing environmental issues like the accumulation of non-biodegradable waste and toxic emissions. However, there is a growing public awareness of the environmental crises related to plastic disposal methods, and people are ready to accept new solutions and alternatives to petro-based plastics. One such solution is the manufacturing of recycled plastic bio-building blocks, which are not only sturdier than concrete but also promote a circular economy and environmental sustainability by reducing waste, energy use, and CO2 emissions.
| Characteristics | Values |
|---|---|
| Materials used | Non-recyclable, landfill-bound plastic waste, sand |
| Plastic types | PET, PEEK, PLA, PVC, and seven other types of which only two are recyclable |
| Synthesis methods | Catalytic conversion of biomass-derived HMF into FDCA, biological route from biomass feedstock into EG |
| Advantages | Reduces waste and energy use, generates less CO2 than concrete, promotes a circular economy, affordable |
| Disadvantages | Wide variation in plastic types can lead to unpredictable strength |
| Applications | Construction, sleepers in marine environments, railroad ties, enclosures, sheds, fencing, landscaping, cinder blocks, bricks |
| Companies | ByFusion, Gjenge Makers |
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What You'll Learn
Using non-recyclable plastic waste to create building blocks
Plastic waste is a highly visible global problem. The world produces around 359 million tonnes of plastic each year, and the environment cannot address its disposal fast enough to prevent harm to living beings. However, plastic waste can be reshaped into a sustainable building material.
ByFusion is a startup that uses a combination of steam and compression to shape all kinds of plastics, even non-recyclables, into standard building blocks called ByBlocks. These blocks can be used to build anything from fences and retaining walls to public terraces and bus stops. The process requires no added chemicals, fillers, or waste, and recycles the unrecyclable without sorting or prewashing. The ByBlocks are made using a machine called a Blocker, which comes in two sizes: one is the size of a shipping container and can process up to 30 tons of plastic per month, while the other is floor-mounted and can process more than 90 tons per month. The Blocker machine carries a significant price tag of $1.3 million, but ByFusion argues that recycling plastic comes with financial challenges, and the cost of dealing with unrecyclable plastic creates a burden for taxpayers.
In 2019, ByFusion partnered with the Hefty EnergyBag program and the city of Boise, asking residents to separate their hard-to-recycle plastics. Although only 20% of residents participated, the effort still collected about 30 tons of plastic grocery bags, bubble wrap, and fast-food containers that were diverted from landfills.
Another example of turning non-recyclable plastic into building blocks is Gjenge Makers in Nairobi, Kenya, which produces around 1500 bricks a day out of a mix of sand and different plastics. The bricks are twice as sturdy as concrete and provide a use for factory waste that cannot be recycled otherwise.
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Mixing sand and plastic to create bricks
Nzambi Matee from Nairobi, Kenya, is the inventor of the plastic brick. The bricks are made from a mixture of sand and plastics. Higher-density plastics are received from factory waste, and lower-density plastics are bought from local recyclers. This process provides a use for factory waste and promotes recycling in the local environment. The plastic that would have been trash for hundreds of years is now a simple, high-quality, and sturdy product.
The sand and plastic are mixed at very high temperatures and then compressed into bricks. The factory Matee founded produces around 1500 bricks a day from a mix of different plastics. The exact ratio of sand to plastic is not publicly available, but the bricks are twice as sturdy as concrete.
There are other companies working on similar projects, such as ByFusion, which has developed a platform to repurpose non-recyclable, landfill-bound plastic waste into an advanced, reusable building material called ByBlock. ByBlock does not use sand, but the process is similar in that it uses waste plastics to create a building material.
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Using plastic waste to create railroad ties
The use of recycled plastic for railroad ties is a viable solution to the environmental crisis caused by the improper disposal of plastic waste. Every year, the United States generates 35.4 million tons of plastic products, with a significant amount ending up in landfills or natural environments, contributing to shrinking landfill capacity and the accumulation of non-degradable waste.
By utilizing reinforced recycled plastic for railroad ties, we can mitigate the harmful effects of plastic waste on our land and oceans. These railroad ties are not only environmentally beneficial but also offer several advantages over traditional wood ties. Firstly, they are completely moisture-resistant, making them suitable for areas with termite infestations, water intrusion, and soft sub-grades. Secondly, they are as strong as hardwood and have a longer lifespan, resulting in lower replacement and maintenance costs. Additionally, they help conserve natural resources such as timber, reduce energy consumption, and support the development of domestic manufacturing and recycling industries.
The process of manufacturing recycled plastic railroad ties involves the use of advanced technologies to reclaim plastic waste. For example, ByFusion's landfill diversion + transparency platform (LDP) repurposes non-recyclable plastic waste into a building material called ByBlock, which can be used for various applications, including railroad ties. Other innovative approaches include mixing sand and plastics at high temperatures to create sturdy bricks, as demonstrated by Nzambi Matee, a materials engineer from Nairobi, Kenya. Matee's company, Gjenge Makers, accepts hard-to-recycle plastic waste from factories and other recyclers, promoting local recycling initiatives and providing jobs in the recycling industry.
The use of recycled plastic for railroad ties is a step towards a more sustainable future. By adopting these practices, we can reduce our reliance on wood, conserve natural resources, and decrease the amount of plastic waste sent to landfills and incinerators. Additionally, the production and use of bio-based polymers, such as PEF, offer promising alternatives to traditional petro-based plastics. These bio-building blocks, derived from biomass feedstock, contribute to the advancement of a circular economy and environmental sustainability.
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Using recycled plastic for structural material
Using recycled plastic as a structural material is a sustainable and cost-effective alternative to traditional building materials. The construction industry is increasingly exploring the use of recycled plastic to reduce its environmental impact and promote a circular economy.
One notable example of using recycled plastic for structural material is the creation of plastic bricks. These bricks are made by mixing sand and plastic at very high temperatures and then compressing the mixture into bricks. Plastic bricks are twice as sturdy as concrete and provide a simple, sustainable solution to plastic waste. They have been used to create affordable, livable homes, with one Colombian company manufacturing and using these bricks to build a house for just over $5,000.
Recycled plastic can also be used as a substitute for steel and wood in construction. Structural plastic lumber, made from recycled plastics, is lighter than steel and longer-lasting than lumber. It has been used in various construction projects, including bridges, docks, bus stops, and railroad ties. By using plastic lumber, there is no need for toxic preservatives that are typically required to protect wood from insects and weather.
In addition to bricks and lumber, recycled plastic can be used for ceiling tiles, providing an easy-to-install and cost-effective way to add value to a home. Using recycled plastic in construction not only reduces waste but also saves space in landfills and lowers costs by reducing the amount of new plastic needed. It also helps reduce greenhouse gas emissions, with estimates suggesting that GCC countries could cut CO2 emissions by 2 to 2.5% by 2040 by using recycled plastics in the building materials sector.
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Using recycled plastic for sleepers in marine environments
Railway sleepers made from recycled plastic offer a more environmentally friendly alternative to concrete sleepers. Recycled plastic sleepers are already in use in some parts of Europe, including Milan, Zurich, and Hanover. They have been proven to be resistant to corrosion and environmental conditions, with a lifespan of up to 60 years.
Recycled plastic sleepers can be made from a variety of plastics, including liquid packaging board and acrylonitrile butadiene styrene. The use of recycled plastic also allows for greater design flexibility in the shape of the sleeper. During installation, ordinary woodworking tools can be used for tasks such as sawing, planing, and screwing.
In a marine environment, the corrosion resistance of recycled plastic sleepers is particularly advantageous. They are also waterproof, insect-proof, and non-toxic. The lateral sliding energy of plastic sleepers is better than that of wooden sleepers, which is beneficial for track stability. Additionally, recycled plastic sleepers have good electrical insulation performance and can withstand adverse weather conditions.
While recycled plastic sleepers have higher emissions during their initial life cycle, they demonstrate the greatest potential for saving GHG emissions in subsequent life cycles. This is due to the reduced carbon emissions associated with the production and maintenance of the necessary infrastructure. Researchers estimate that the CO2 reduction achieved by using recycled plastic sleepers in Finland could be equivalent to the heating emissions of 1,200 households.
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Frequently asked questions
Recycled plastic building blocks are blocks made from plastic waste that can be used as a feasible building material. They are a sustainable alternative to concrete and petro-based plastics.
Recycled plastic building blocks are made by mixing sand and plastics at very high temperatures and then compressing the mixture into blocks. The plastic waste is first shredded and then fused into solid blocks using steam and compression.
Recycled plastic building blocks offer a more environmentally friendly alternative to concrete. They are made from plastic waste, reducing the amount of plastic that ends up in landfills or natural environments. Additionally, the production of these blocks generates less CO2 than concrete production.
